CA1261515A - Blend of wholly aromatic polyester and poly (ester-amide) capable of exhibiting an anisotropic melt phase - Google Patents
Blend of wholly aromatic polyester and poly (ester-amide) capable of exhibiting an anisotropic melt phaseInfo
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- CA1261515A CA1261515A CA000495114A CA495114A CA1261515A CA 1261515 A CA1261515 A CA 1261515A CA 000495114 A CA000495114 A CA 000495114A CA 495114 A CA495114 A CA 495114A CA 1261515 A CA1261515 A CA 1261515A
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L67/00—Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
- C08L67/04—Polyesters derived from hydroxycarboxylic acids, e.g. lactones
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L77/00—Compositions of polyamides obtained by reactions forming a carboxylic amide link in the main chain; Compositions of derivatives of such polymers
- C08L77/10—Polyamides derived from aromatically bound amino and carboxyl groups of amino-carboxylic acids or of polyamines and polycarboxylic acids
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K19/00—Liquid crystal materials
- C09K19/04—Liquid crystal materials characterised by the chemical structure of the liquid crystal components, e.g. by a specific unit
- C09K19/38—Polymers
- C09K19/3804—Polymers with mesogenic groups in the main chain
- C09K19/3809—Polyesters; Polyester derivatives, e.g. polyamides
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- Manufacture Of Macromolecular Shaped Articles (AREA)
Abstract
BLEND OF WHOLLY AROMATIC POLYESTER
AND POLY(ESTER-AMIDE) CAPABLE OF
EXHIBITING AN ANISOTROPIC MELT PHASE
Abstract of the Disclosure A polymer blend which is capable of exhibiting an anisotropic melt phase and the ability to form shaped articles having improved mechanical properties is provided. The improved polymer blend comprises approximately 5 to approximately 95 percent by weight, based upon the total weight of the polymer blend, of a melt-processable wholly aromatic polyester which is substantially free of amide linkages and approximately 5 to approximately 95 percent by weight, based upon the total weight of the blend, of a melt-processable poly(ester-amide). Each of the polymeric components apart from the blend is capable of exhibiting an anisotropic melt phase. Upon injection molding, articles formed from the improved polymer blend surprisingly exhibit at least one property selected from the group consisting of tensile strength, tensile modulus, flexural strength and flexural modulus which exceeds that of each of the polymeric components of the blend when separately injection-molded. The polymer blend of the present invention also can be used to advantage to form improved melt-extruded three-dimensional articles, etc.
AND POLY(ESTER-AMIDE) CAPABLE OF
EXHIBITING AN ANISOTROPIC MELT PHASE
Abstract of the Disclosure A polymer blend which is capable of exhibiting an anisotropic melt phase and the ability to form shaped articles having improved mechanical properties is provided. The improved polymer blend comprises approximately 5 to approximately 95 percent by weight, based upon the total weight of the polymer blend, of a melt-processable wholly aromatic polyester which is substantially free of amide linkages and approximately 5 to approximately 95 percent by weight, based upon the total weight of the blend, of a melt-processable poly(ester-amide). Each of the polymeric components apart from the blend is capable of exhibiting an anisotropic melt phase. Upon injection molding, articles formed from the improved polymer blend surprisingly exhibit at least one property selected from the group consisting of tensile strength, tensile modulus, flexural strength and flexural modulus which exceeds that of each of the polymeric components of the blend when separately injection-molded. The polymer blend of the present invention also can be used to advantage to form improved melt-extruded three-dimensional articles, etc.
Description
~ th _ ventio_ When a blend or mixture ls prepared from two or more ordinary, non-polymerlc materials, a random distribution of the molecules of the components is obtained. This random distribution provides complete mixing without the formation of groups or clusters of the molecules of any one component. Such a mixture is expected to follow the "Rule of Mixtures.~ The Rule of Mixtures predicts the numerical values of properties, such as tensile and flexural strengths and tensile and flexural moduli, of a blend to be ~he weighted average of the numerical values of the properties of the components, A discussion of the Rule of Mixtures can be found in the book ~
Mixtures- Mixture Rules in Science and Enqineerinq, by hawrence E. ~ielsen, Marcel Dekker, Inc. (New York~ 1974~
Further information with regard to the Rule of Mixtures can be found on pages 395, 436, 465~ 492, and 500 of Volume 2 of ~ , by Lawrence E.
Neilsen, Marcel Dekker, ~nc. (New York: 1974). As stated therein, mixtures of a polymer matrix with a f~brous relnforcing agent, a ribbon-shaped filler, or a rod-shaped filler are known to often follow the Rule of Mixtures. The above-cited reference further discloses that mixtures of phase inverted isotroplc interpenetratlng polymer networks, such as a phase inverted network of polystyrene and polybutadiene, are also known to follow the Rule of ~ixtures.
Mixtures of most chemically distinct polymeric materials have been found to devlate from the bebavior of ordinary mixtures as characterized by the Rule of Mixtures. The ,' ' ' ~
sheer size of polymeric chains restricts mixing of the components and leads to the formation of domains or clusters of molecules of the individual components. Thus, it can be said that most chemi-cally distinct polymeric materials tend to be incompatible in mixtures and exhibit a tendency to separate into phases. There often exists a boundary between the domains of the component polymers, and articles made from such a blend would be expected to exhibit failure at the boundary when placed under stress. In general, then, the mechanical properties of the product are com-monly reduced rather than enhanced. Specific properties which may be thus affected include tensile strength, tensile modulus, flexural strength, flexural modulus, and impact strength.
Some polymeric materials exhibit an ordered structure in at least some regions of the polymer. This order can exist in one, two, oc three dimensions. Th~ inclusion in blends of polymeric materials exhibiting an ordered structure leads to an increased tendency of the blends to separate into phases. This is due to the fact that the order found in certain regions of the polymer causes a fairly sharp boundary between the domains of the molecules of the component polymers. Thus, blends including such polymers could be expected to exhibit a slgnificant reduction in mechanical properties. Accordingly, there has been little impetus to form such blends, particularly for u~e in applications where mechanical properties are of importance.
Representative disclosures of polymer blends which may include at least one polymeric component that is capable of fcrming an ordered or anisotropic structure in the melt phase are found in United States Patent Nos. 4,228,218; 4,267,28g;
4,276,397; 4,386~174; 4,408,022; 4,451,611; 4,460,735; and ., , 71Q12-~
4,~60,736; ~uropean Patent Application ~o~ 0041327 published December 9, 1981; and in commonly assigned United States Patent No. ~,489,190, issued on December 18, 1984, and Canadian Patent Application Serial No. f~58,422. In United States Patent No.
~,386,174 ~t Col. ~, lines 47 to 49, poly(ester-amides) capable oE forming an anisotropic melt phase are identified in passing as being anisotropic melt-forming polymers which can be used to render another polymer melt-processable. ~lsol commonly assigned United S-tates Patent No. ~,267,289 contemplates form-ing a polymer blend from a pair of specifically defined whollyaromatic polyesters which are each melt-processable in the absence of the o-ther and are each capable of Eorming an aniso-tropic melt phase.
It is an object of the presen-t inven-tion to provide an improved melt-processable polymer blend which is capable of forming an anisotropic melt phase.
It is an object of the present invention to provide an improved polymer blend wherein a synergism has been found to exist between the polymer blend components which leads -to an ability to form shaped articles from the same that exhibit surprisingly outstanding mechanical properties.
It is an object of the present invention to provide an improved polymer blend which can be used to advantage to form improved molded articles, improved melt-extruded three-dimensional articles, etc.
It is an object of the present invention to provide an improved polymer blend which following injection-molding is capable of exhibiting at least one mechanical property (e.g., tensile strength, tensile modulus, flexural strength, or flex-ural modulus) which exceeds that of each of the polymericcomponents of the blend when separately injection-molded.
~ ~ 3-~,`1 It i~ another object of the present invention to provide an improved polymer blend which is morphologically homogeneous and which has been found to possess a rheology amenable to the formation of improved shaped articles ~e.g., a blend melt viscosity which i8 lower than that of each of the polymeric blend components~.
It is a further object of the present invention to provide improved shaped articles such as improved injection-molded articles, improved melt-extruded three-dimensional articles, etc., formed from the polymer blend of the present invention~
These and other objects, as well as the scope, nature and utilization of the claimed invention, will be apparent to those skilled in the art from the following detailed description and appende~ claims:
Summary of _he Invention It has been found that a polymer blend formed by melt-mixing which when molten is capable of exhibiting an anisotropic melt phase and which following lnjection-molding is capable of exhibiting at least one property selected from the group consisting of tensile strength, tensile modulus, flexural strength and flexural modulus which exceeds that of each of the polymeric components of the blend when separately injection-molded comprises:
~a) approximately 5 to approximately 95 percent by weight, based upon a total weight of components (a) and ~b), of a melt-processable wholly aromatic polyester s~hich is capable of forming an anisotropic melt phase and which is substantially free of amide linkages; and ~b) approximately 5 to approximately 95 percent by weight, based upon the total weight of components Ca) and ~b), of a melt-processable poly~ester-amide) which i5 capable of forming an anisotropic melt phase.
Descri~tion of Preferred Embodiments The first component of the polymer blend of the present invention is a melt-processable wholly aromatic polyester which is capable of forming an anisotropic melt phase and which is substantially free of amide linkages. 5uch polymer is melt-processable in the sense that it exhibits a melting temperature below i~s decomposition or degradation temperature and can be satisfactorily injection-molded or melt-extruded to form shaped articles apart from the blend of the present invention. Such polymer is wholly aromatic in the sense that each monomer which is polymerized to form the polymer backbone contributeæ at least one aromatic ring. In a preferred embodiment the first component of the polymer blend contains no amide linkages in the polymer backbone.
The anisotropic melt-forming wholly aromatic polyesters which can serve a~ the first component in the polymer blend of the present invention are known to those skilled in polymer technology, These polymers have been described by various terms including "liquid crystalline,~ liquid crystal, n ~thermotropic,~
~mesomorphic,n ~anisotropic," e~c. Such polymers inherently exhibit a parallel ordering of the polymer chains when the polymer is molten even in ~he static state. This parallel ordering of the molten polymer chains may be confirmed by conventional polarized light techniques whereby crossed polarizers are utilized. More specifically, the anisotropic melt phase may be confirm~d by the use of a Leitz polarizing microscope at a magnification of 40X with the sample on a Leitz hot stage and under a nitrogen atmosphrere. The anisotropic character of the polymer melt is detected when the polymer melt transmits light while being examined in the static state between crossed polarizersO
As will be ~pparent to those skilled in polymer technology, the f irst component of the polymer blend commonly is prepared from monomers which are generally long, flat and fairly rigid along the long axis of the molecule and commonly have chain-extending linkages that are either coaxial or parallel.
The reactive moieties which are utilized to form the wholly aromatic polyester commonly are aromatic diols, aromatic diacids, and aromatic hydroxyacids, or their derivatives.
The aromatic rings included in the polymer chains of the first component of the polymer blend may optionally include substitution of at lea~t some of the hydrogen atoms present upon the aromatic r~ng Such substituents include alkyl groups of up to four carbon atoms, alkoxy groups of up to four carbon atoms, halogens, phenyl (including substituted phenyl), etc. Preerred halogens lnclude fluorine, chlorine and bromine. Also, in another preferred embodiment the aromatic rings of the first component of the polymer ~lend are substantially free of ring substitutionO
71012-~8 Represen-tative melt-processable anisotropic mel~-forming wholly aromatic polyestexs which may be selected to serve as the first component of the polymer blend of the present invention are disclosed in United States Patent ~os.
3,991,013; 3,991,014; 4,066,620; ~,0~7,852; 4,075,262;
4,083,~29; ~,118,372; ~,130,545; 4,1~6,702; 4,153,779;
~,156,070; 4,159,365: ~,161,470, 4,169,933, 4,181,792, 4,183,~95; ~,184,996; 4,L8~,476; 4,201,856; 4,219,461;
4,224,433; ~,238,598; 4,238,599; 4,232,143; 4,232,14~;
4,238,600; 4,242,496; 4,245,082; 4,247,514: 4,256,624;
~,265,802; 4,267,304; 4,269,965; 4,279,803; 4,294,955;
4,299,756, 4,318,841; 4,335,232; 4,337,190; ~,337,191;
4,347,349; 4,355,134; 4,359,569; 4,360,658; 4,370,466;
4,375,530; 4,429,100; and 4,473,682.
The melt~processable wholly aromatic polyester suit--able for use as the first component of the polymer blend in the present inven-tion may be formed by a variety of ester-forming techniques whereby organic monomer compounds possessing func--tional groups which, upon condensation, form the requisite recurring moieties are reacted. For instance, the functional groups of the organic monomer compounds may be carboxylic acid groups, hydroxyl groups, ester groups, acyloxy groups, acid halides, etc. The organic monomer compounds may be reacted in the absence of a heat exchange fluid via a melt acidolysis procedure. They, accordingly, may be heated initially to form a melt solution of the reactants with the reaction continuing as the polymer particles are suspended therein. A vacuum may be applied to facilitate removal of vola-tiles formed during the final stage of -the condensation (e.g. acetic acid or water).
J~ 71173-83 Alternatively, it is possible to form the wholly aro~atic polyester via a slurry polymerization process with the product being suspended in a heat exchange medium such as described in United States Patent No. 4,083,~29.
When employing either the melt acidolysis procec~ure or the slurry polymerizatiorl procedure, the organic monomer reactant~s ~rom which the wholly aromatic polyester is derived pre~erably may be initially provided in a modified form whereby the usual hydroxyl groups of the monomers are esterified (i.e., they are provided as lower acyl esters). Such lower acyl groups commonly have from about two to about four carbon atoms.
Most preferably, the acetate esters of the organic monomer reactants are provided. Catalysts optionally may be employed in either -the melt acidolysis procedure or in the slurry polymerization procedure.
The melt-processabLe wholly aromatic polyesters capable of forming the first component of the polymer blend tend to be substantially insoluble in common solvents and accordingly are not susceptible to solution processing. As discussed previously, they can be readily processed by common melt-processing techniques. Most suitable wholly aromatic polyesters are soluble in pentafluorophenol to a limited degree.
The melt-processable wholly aromatic polyesters commonly exhibit a weight average molecular weight of about
Mixtures- Mixture Rules in Science and Enqineerinq, by hawrence E. ~ielsen, Marcel Dekker, Inc. (New York~ 1974~
Further information with regard to the Rule of Mixtures can be found on pages 395, 436, 465~ 492, and 500 of Volume 2 of ~ , by Lawrence E.
Neilsen, Marcel Dekker, ~nc. (New York: 1974). As stated therein, mixtures of a polymer matrix with a f~brous relnforcing agent, a ribbon-shaped filler, or a rod-shaped filler are known to often follow the Rule of Mixtures. The above-cited reference further discloses that mixtures of phase inverted isotroplc interpenetratlng polymer networks, such as a phase inverted network of polystyrene and polybutadiene, are also known to follow the Rule of ~ixtures.
Mixtures of most chemically distinct polymeric materials have been found to devlate from the bebavior of ordinary mixtures as characterized by the Rule of Mixtures. The ,' ' ' ~
sheer size of polymeric chains restricts mixing of the components and leads to the formation of domains or clusters of molecules of the individual components. Thus, it can be said that most chemi-cally distinct polymeric materials tend to be incompatible in mixtures and exhibit a tendency to separate into phases. There often exists a boundary between the domains of the component polymers, and articles made from such a blend would be expected to exhibit failure at the boundary when placed under stress. In general, then, the mechanical properties of the product are com-monly reduced rather than enhanced. Specific properties which may be thus affected include tensile strength, tensile modulus, flexural strength, flexural modulus, and impact strength.
Some polymeric materials exhibit an ordered structure in at least some regions of the polymer. This order can exist in one, two, oc three dimensions. Th~ inclusion in blends of polymeric materials exhibiting an ordered structure leads to an increased tendency of the blends to separate into phases. This is due to the fact that the order found in certain regions of the polymer causes a fairly sharp boundary between the domains of the molecules of the component polymers. Thus, blends including such polymers could be expected to exhibit a slgnificant reduction in mechanical properties. Accordingly, there has been little impetus to form such blends, particularly for u~e in applications where mechanical properties are of importance.
Representative disclosures of polymer blends which may include at least one polymeric component that is capable of fcrming an ordered or anisotropic structure in the melt phase are found in United States Patent Nos. 4,228,218; 4,267,28g;
4,276,397; 4,386~174; 4,408,022; 4,451,611; 4,460,735; and ., , 71Q12-~
4,~60,736; ~uropean Patent Application ~o~ 0041327 published December 9, 1981; and in commonly assigned United States Patent No. ~,489,190, issued on December 18, 1984, and Canadian Patent Application Serial No. f~58,422. In United States Patent No.
~,386,174 ~t Col. ~, lines 47 to 49, poly(ester-amides) capable oE forming an anisotropic melt phase are identified in passing as being anisotropic melt-forming polymers which can be used to render another polymer melt-processable. ~lsol commonly assigned United S-tates Patent No. ~,267,289 contemplates form-ing a polymer blend from a pair of specifically defined whollyaromatic polyesters which are each melt-processable in the absence of the o-ther and are each capable of Eorming an aniso-tropic melt phase.
It is an object of the presen-t inven-tion to provide an improved melt-processable polymer blend which is capable of forming an anisotropic melt phase.
It is an object of the present invention to provide an improved polymer blend wherein a synergism has been found to exist between the polymer blend components which leads -to an ability to form shaped articles from the same that exhibit surprisingly outstanding mechanical properties.
It is an object of the present invention to provide an improved polymer blend which can be used to advantage to form improved molded articles, improved melt-extruded three-dimensional articles, etc.
It is an object of the present invention to provide an improved polymer blend which following injection-molding is capable of exhibiting at least one mechanical property (e.g., tensile strength, tensile modulus, flexural strength, or flex-ural modulus) which exceeds that of each of the polymericcomponents of the blend when separately injection-molded.
~ ~ 3-~,`1 It i~ another object of the present invention to provide an improved polymer blend which is morphologically homogeneous and which has been found to possess a rheology amenable to the formation of improved shaped articles ~e.g., a blend melt viscosity which i8 lower than that of each of the polymeric blend components~.
It is a further object of the present invention to provide improved shaped articles such as improved injection-molded articles, improved melt-extruded three-dimensional articles, etc., formed from the polymer blend of the present invention~
These and other objects, as well as the scope, nature and utilization of the claimed invention, will be apparent to those skilled in the art from the following detailed description and appende~ claims:
Summary of _he Invention It has been found that a polymer blend formed by melt-mixing which when molten is capable of exhibiting an anisotropic melt phase and which following lnjection-molding is capable of exhibiting at least one property selected from the group consisting of tensile strength, tensile modulus, flexural strength and flexural modulus which exceeds that of each of the polymeric components of the blend when separately injection-molded comprises:
~a) approximately 5 to approximately 95 percent by weight, based upon a total weight of components (a) and ~b), of a melt-processable wholly aromatic polyester s~hich is capable of forming an anisotropic melt phase and which is substantially free of amide linkages; and ~b) approximately 5 to approximately 95 percent by weight, based upon the total weight of components Ca) and ~b), of a melt-processable poly~ester-amide) which i5 capable of forming an anisotropic melt phase.
Descri~tion of Preferred Embodiments The first component of the polymer blend of the present invention is a melt-processable wholly aromatic polyester which is capable of forming an anisotropic melt phase and which is substantially free of amide linkages. 5uch polymer is melt-processable in the sense that it exhibits a melting temperature below i~s decomposition or degradation temperature and can be satisfactorily injection-molded or melt-extruded to form shaped articles apart from the blend of the present invention. Such polymer is wholly aromatic in the sense that each monomer which is polymerized to form the polymer backbone contributeæ at least one aromatic ring. In a preferred embodiment the first component of the polymer blend contains no amide linkages in the polymer backbone.
The anisotropic melt-forming wholly aromatic polyesters which can serve a~ the first component in the polymer blend of the present invention are known to those skilled in polymer technology, These polymers have been described by various terms including "liquid crystalline,~ liquid crystal, n ~thermotropic,~
~mesomorphic,n ~anisotropic," e~c. Such polymers inherently exhibit a parallel ordering of the polymer chains when the polymer is molten even in ~he static state. This parallel ordering of the molten polymer chains may be confirmed by conventional polarized light techniques whereby crossed polarizers are utilized. More specifically, the anisotropic melt phase may be confirm~d by the use of a Leitz polarizing microscope at a magnification of 40X with the sample on a Leitz hot stage and under a nitrogen atmosphrere. The anisotropic character of the polymer melt is detected when the polymer melt transmits light while being examined in the static state between crossed polarizersO
As will be ~pparent to those skilled in polymer technology, the f irst component of the polymer blend commonly is prepared from monomers which are generally long, flat and fairly rigid along the long axis of the molecule and commonly have chain-extending linkages that are either coaxial or parallel.
The reactive moieties which are utilized to form the wholly aromatic polyester commonly are aromatic diols, aromatic diacids, and aromatic hydroxyacids, or their derivatives.
The aromatic rings included in the polymer chains of the first component of the polymer blend may optionally include substitution of at lea~t some of the hydrogen atoms present upon the aromatic r~ng Such substituents include alkyl groups of up to four carbon atoms, alkoxy groups of up to four carbon atoms, halogens, phenyl (including substituted phenyl), etc. Preerred halogens lnclude fluorine, chlorine and bromine. Also, in another preferred embodiment the aromatic rings of the first component of the polymer ~lend are substantially free of ring substitutionO
71012-~8 Represen-tative melt-processable anisotropic mel~-forming wholly aromatic polyestexs which may be selected to serve as the first component of the polymer blend of the present invention are disclosed in United States Patent ~os.
3,991,013; 3,991,014; 4,066,620; ~,0~7,852; 4,075,262;
4,083,~29; ~,118,372; ~,130,545; 4,1~6,702; 4,153,779;
~,156,070; 4,159,365: ~,161,470, 4,169,933, 4,181,792, 4,183,~95; ~,184,996; 4,L8~,476; 4,201,856; 4,219,461;
4,224,433; ~,238,598; 4,238,599; 4,232,143; 4,232,14~;
4,238,600; 4,242,496; 4,245,082; 4,247,514: 4,256,624;
~,265,802; 4,267,304; 4,269,965; 4,279,803; 4,294,955;
4,299,756, 4,318,841; 4,335,232; 4,337,190; ~,337,191;
4,347,349; 4,355,134; 4,359,569; 4,360,658; 4,370,466;
4,375,530; 4,429,100; and 4,473,682.
The melt~processable wholly aromatic polyester suit--able for use as the first component of the polymer blend in the present inven-tion may be formed by a variety of ester-forming techniques whereby organic monomer compounds possessing func--tional groups which, upon condensation, form the requisite recurring moieties are reacted. For instance, the functional groups of the organic monomer compounds may be carboxylic acid groups, hydroxyl groups, ester groups, acyloxy groups, acid halides, etc. The organic monomer compounds may be reacted in the absence of a heat exchange fluid via a melt acidolysis procedure. They, accordingly, may be heated initially to form a melt solution of the reactants with the reaction continuing as the polymer particles are suspended therein. A vacuum may be applied to facilitate removal of vola-tiles formed during the final stage of -the condensation (e.g. acetic acid or water).
J~ 71173-83 Alternatively, it is possible to form the wholly aro~atic polyester via a slurry polymerization process with the product being suspended in a heat exchange medium such as described in United States Patent No. 4,083,~29.
When employing either the melt acidolysis procec~ure or the slurry polymerizatiorl procedure, the organic monomer reactant~s ~rom which the wholly aromatic polyester is derived pre~erably may be initially provided in a modified form whereby the usual hydroxyl groups of the monomers are esterified (i.e., they are provided as lower acyl esters). Such lower acyl groups commonly have from about two to about four carbon atoms.
Most preferably, the acetate esters of the organic monomer reactants are provided. Catalysts optionally may be employed in either -the melt acidolysis procedure or in the slurry polymerization procedure.
The melt-processabLe wholly aromatic polyesters capable of forming the first component of the polymer blend tend to be substantially insoluble in common solvents and accordingly are not susceptible to solution processing. As discussed previously, they can be readily processed by common melt-processing techniques. Most suitable wholly aromatic polyesters are soluble in pentafluorophenol to a limited degree.
The melt-processable wholly aromatic polyesters commonly exhibit a weight average molecular weight of about
2,000 to 200,000, and preferably about 10,000 to 50,000, and most preferably about 20,000 to 25,000. Such molecular weight may be determined by gel permeation chromatography as well as by other standard techniques not involving the solutioning of the polymer 71012-A~
~ ~, by end group determination via infrared spectroscopy on compression molded films). Alternatively, light scattering techniques in a penta~luorophenol solution may be employed to determine the molecular weight.
The melt-processable wholly aromatic polyester which serves as the first component oE the polymer blend commonly exhibits an inherent viscosity (i.e. I.V.) of at least approxim~tely 2.0 dl./g. (e.g., approximately 2.0 to 12.0 cll./g.) when dissolved in a concentration of 0.1 percent by weight in pentafluorophenol at 60C.
In a preferred embodiment of the present invention the melt-processable wholly aromatic polyester is that of commonly assigned United States Patent No. 4,161,470. In such embodiment the melt-processable wholly aromatic polyester consists essentially of moieties I and II which may include suhstitution of at least some of the hydrogen atoms present upon an aromatic ring wherein:
I is ~ c , and ~
II is ~ ~-with said optional substitution if present being selected from ~ 20 the group consisting oE an alkyl group o~ 1 to 4 carbon atoms, an alkoxy group of 1 to 4 carbon atoms, halogen, phenyl, and mixtures thereof, and wherein said wholly aromatic polyester comprises approximately 10 to 90 mole percent of moeity I and approximately 10 to 90 mole percent of moiety II. In a preferred embodment the aromatic rings of the wholly aromatic polyester are substantially free of ring sub~titution. Also, in a preferred embodiment the wholly aromatic polye~ter compri~es approximately 15 to 35 mole percent of moiety I and approximately 65 to as mole percent of moiety II. In a particularly preferred embodi~ent the wholly aromatic polyester consists essentially of approximately 27 mole percent of recurring 6-oxy-2-naphthoyl moieties and approximately 73 mole percent of recurring 4-oxybenzoyl moieties.
The second component of the polymer blend of the present invention i~ a melt-processable poly(ester-amide) which is capable of formlng an anisotropic melt phase. Such polymer also is melt-processable in the sense that it exhibits a melting ~emperature below its decomposition or degradation temperature and can be satisfactorily injection-molded or melt-extruded to form shaped articles apart from the blend of the present invention. Such poly(ester-amide) preferably i~ wholly aromatic in the sense that each monomer which i5 polymerized to form the polymer backbone contribute~ at least one aromatic ring. The anisotropic character of the melt phase can be confirmed as discussed with respect to the wholly aromatic polyester blend component~
The anisotropic melt-forming poly(ester-amides) which can serve as the second component in the polymer blend of the present invention are al50 known to tho~e skilled in polymer technology~ Such poly(ester-amides) are also generally prepared from monomers which are long, flat and fairly rigid along the long axis of the molecules and commonly have chain-extending 71012-4~
5~i linkages that are nei-ther coaxial or parallel. The reactive moieties untili~ed to form the poly(ester-amides) commonly are aromatic amines, aromatic diols, aromatlc or cyclohexylene diacids, and aromatic hydroxyacids, or their derivatives. The aromatic rings included in the polymer chains may optionally include substitution as previously described in conjunction with the wholly aromatic polyester blend component.
Representa-tive melt-processable aniso-tropic melt-forming poly(ester-amides) which may be selected to service as the second component of the polymer blend are disclosed in Uni-ted States Patent Nos. 4,272,625; 4,330,457; 4,339,376;
4,341,688; 4,351,917; 4,351,918; and 4,355,132.
The poly(ester-amide) blend component generally may be formed by the same polymerization routes described in con-junction with the wholly aromatic polyester blend component with amine reactive monomer groups (or amine derivatives) being substituted in whole or in part for hydroxyl reactive monomer groups (or their derivatives).
The melt-processable poly(ester-amides) capable of ~0 Eorming the second component of the polymer blend also tend to be subs-tantially insoluble in common solvents and accordingly are not susceptible -to solution processing. As discussed previously, they can be reaclily processed by common melt-processing techniques. ~ost suitable poly(ester-amides) are soluable in pen-tafluorophenol to a limi-ted degree.
The melt-processable poly(ester-amides) commonly exhibit a weiyht average molecular weight of about 2,000 to 200,000, and preferably about 10,000 to 50,000, and most ".~
~2~ 710~2-~8 perferably about 20,000 to 25,000. Such molecular weiyhts can be determined as described in conjunction with the wholly aromatic polyester blend component.
The melt~processable poly(ester-amide) which serves as the second co~lponent of the polymer blend commonly exhibits an inherent viscosity (i~e., I.V.) of at least approximately 2.0 dl./g. (e.g., approximately 2.0 to 12.0 dl./g.) when dissolved in a concentration of 0.1 percent by weight in pentafluorophenol at 60C. In a particularly preferred embodiment the poly(ester-amide) blend component exhibits and inherent viscosity of approximately 3 to 6 dl./g. when examined via such I.V. determination.
In a preferred embodiment of the present invention the melt-processable poly(ester-amide) is that of commonly assigned United States Patent No. 4,330,457. In such embodiment the melt-processable poly(ester-amide) consists essentially of moieties I, II, III, and optionally IV, wherein:
I is ~ ~~
O O
II is- C - A - C -, ~ 20 where A is a divalent radical comprising at least one aromatic ring or a divalent trans-l,~-cyclohexylene radical, III is - Y - Ar - Z - where Ar is a divalent radical comprising at least one aromatic ring, Y is 0, NH
or NR, and Z i8 NH or NR, where R is an alkyl group of l to 6 ~arbon atoms; and IV i~ - 0 - Ar' - 0 - where Ar' i~ a divalent radical comprising at least one aromatic ring;
wherein at least some of the hydrogen atoms present upon the rings optionally may be replaced by substitution selected from the group consisting of an alkyl group of l to 4 carbon atoms, an alkoxy group of l to 4 carbon atom~, halogen, phenyl, and mixtures thereof, and wherein said poly(ester-amide~ comprises approximately lO to 90 mole percent of moiety I, approximately 5 to 45 mole percent of moiety II, appro~imately 5 to 45 ~ole percent of moiety III, and approximately 0 to 40 mole percent of moiety IV~ In a preferred embodiment the aromatic rings of the poly(ester-amide) are substantially free of ring substitution.
Also, in a preferred embodiment the poly~ester-amide) i~ wholly aromatic.in the sense that each monomer which is polymerized to form the polymer contributes at least one aromatic ring.
Addi~ionally, in a preferred embodiment the poly(ester-amide) comprises approximately 40 to 80 mole percent of moiety I, approximately 5 to 30 mole percent of moiety II, approxim~tely 5 to 30 ~ole percent of moiety III, and approximately 0 to 40 mole percent of moiety IV. In a particularly preferred embodiment the poly~ester-amide) conslsts essentially of approximately 60 mole percent of recurring 6-oxy-2-naphthoyl moieties, appro~imately 20 mole percent of recurring terephthaloyl moieties, and approximately 20 ~ole percent of 4-oxyaminophenylene moieties.
The polymer blend of the present invention has been found to be morphologically homogeneous in that when an exposed surface of a broken test ~pecimen formed from the same is examined by scanning electron microscopy at a magnification of 2000X, no dlscrete domains of each polymeric component are apparent. Also, the polymer blend of the pxesent invention commonly has been found to exhibit unusually low melt viscosity values. Such melt viscosity at low shear rates typically is lower than that of each of the polymeric blend components. For instance, a representative wholly aromatic polyester of U.S.
Patent ~o. 4,1~1,470 was found to exhibit a melt viscosity of approximately 4788 poise at a shear rate of 10 secO 1~ and a representative poly(ester-amide) of ~.S. Patent No. 4,330,457 was found to exhibit a melt viscosity of appro~imately 5737 pols~ at a shear rat~ of 10 sec.~l. When 70 percent by weight of the wholly aromatic polyester was melt blended with 30 percent by weight of the poly~ester-amide~, the blend melt visco~ity dropped to appro~imately 4301 poise at a shear rate of 10 sec. 1.
Additlonally, when 30 percent by weight of the wholly aromatic.
polyester was melt blended with 70 percent by weight of the poly(e~ter-amide), the blend melt vi~cosity dropped even urther to approximately 2fiO6 poise at a shear rate of 10 sec. 1.
~ he polymer blend of the present invention comprises appro~imately 5 to approximately 95 percent by weight of the wholly aromatic polyester and approximately 5 to 95 percent by weight of the poly~ester-amide) based upon the total weight of these components. ~or~ spe~ifically~ the polymer blend may comprise approximately 20 to approxlmately 80 percent by weight of the wholly aromatic polyester and approximately 20 to approximately 80 percen~ by weight of the poly(ester-amide) based upon the total weight of these components. In a more preferred embodiment o the present invention the polymer blend comprises approxima~ely 25 to approximately 75 percent by weight of the wholly aromatic polyester and approximately 25 to approximately 75 percent by weight of the poly(ester-amide) based upon the Cor~ n,~ 5 total weight of these 44~pe~e~. In a particularly preferred embodiment the polymer blend comprises approximately 30 percent by weight of the wholly aromatic polyester and approximately 70 percent by weight of the poly(ester-amide3. ~ach of the above weight percentages for the polymeric components of the blend is exclusive of additionally added components, such as reinforcing agents, fillers, etc., which are discussed hereafter.
The polymer blend of the present invention may optionally Lncorporate approximately 1 to approximately 60 percent by weigh~ (preferably approximately 10 to 30 percent by weight), based upon the total weight of the molding composition, i of a solid filler and/or reinforcing agent. Representative filler materials include calcium silicate, silica, clays, talc, mica, poly~etrafluoroethylene, graphite, alumina trihydrate, sodium aluminum carbonate, barium ferrite, etc. Representative reinforcing fibers include glass fibers, asbestos, graphitic carbon fibers, amorphou~ carbon fibers, synthetic polymeric fiber~, alumina fiberst aluminum silicate fibers, alu~inum oxide fibers, titanium fibers, ~agnesium fibers, rock wool fibers, steel fiber~ tungsten fiber-~, cotton, wool, wood cellulose fibers, ets~ The relatively low melt viscosity of th~ polymeric blend enables substantLal concentrations of a solid filler and/or reinforcing agent to be added without rai~ing the melt viscosity to unacceptably high levels.
The improved polymer blend of the present invention is formed by mixing the wholly aromatis polyester and poly(ester-amide) components while each i~ in the Molten ~tate. For instance, lnitially the polymeric component~ can be individually provided in the form of solid chips or pellets ~ach of the components can be separately we~ghed, and then physically mixed together in an appropriate apparatus (~ a ball mill). If a solid filler and/or reinforcing agent is to be incorporated within the polymer blend, it too can be physically admixed with the solid polymer components at this point in time. The physical admixture of the solid polymeric blend components preferably is next dried. Such drying convenien~ly can be conducted in a vacuum oven or in a circulating air oven, although any suitable apparatus may be usedO The purpose of the drying step is to remove water from the physical mixture so as to prevent water-initiated degradation of the polymers during the melt-blending operation. After the mixture of solid polymer particles has been dried, a substantially uniform polymer melt blend can then be prepared. A convenient method for forming the polymer ~elt bl~nd 1~ by melt-extrusion. The extrusion apparatu~ thoroughly mixes the polymers in the melt and then extrudes the blend in the form of a strand which upon solidification can be cut or broken into cbips or pellets which are suitable to form improved shaped articles. Alternatively, discrete pellets of each of the polymer blend components can be fed to the hopper of an injection-molding machine with the desired melt-blending being accomplished by the plasticating action of the screw of the injection-molding machine.
~6~5~L5i The polymer blend of the present invention commonly is capable of being melt-processed at a temperature in the range of approximately 250C, to 400C. In a preferred embodiment of the present invention the polymer blend is capable of being melt processed at a temperature in the range of approximately'260C.
to 350C. In a more preferred embodiment of the present invention, the polymer blend is capable of being melt-processed at a temperature in the range of approximately 280C. to 330C.
In the most preferred embodiment of the present invention the polymer blend is capable of being melt-processed at a temperature in the range of approximately 2~0C. to 300C.
It has been found that the polymer blend of the present invention can be used to form shaped articles which have surprisingly outstanding mechanical properties while using conventiona, shaped article~forming techniques. Such shaped articles can be in the configuration of improved molded articles ~i.e., three-dimensional molded articles), improved melt-extruded three-dimensional articles (~ ~, rods or pipes), etc.
Shaped three-dlmensional articles can be formed from the polymer blend of the present invention while using injection-molding technology. For instance, a preferred molten melt blend of the present invention while at a temperature of approximately 300Co and under a pressure of approximately 1,000 to 20,000 psi (e.g., approximately 3,000 to 10,000 psi) may be injected into a mold cavity. The mold cavity commonly is maintained at a temperature of approximately 25 to 150C. (~ , approximately lG0C.). The cycle time (i.e., the time between injections) for the polymer blend commonly is approximately 10 to 120 seconds.
When standard test bars are formea by injection-molding the polymer blend oE the present invention and are tested, they are found to exhibit surprisingly outstanding mechanical proper-ties. The standard test bars can possess dimensions of 0u076 x .125 x 3 inches (one inch gauge length) or 0.125 x 0.5 x 5 inches (two inch gauge length) and their tensile strength and tensile modulus values can be determined in accordanc~ with the standard ASTM D638 procedure~ The flexural properties of the test bars (i.e.~ flexural strength and flexural modulus) can be determined in a~cordance with the procedure of ASTM D790.
Tensile strength values of at least 35,000 psi preferably are exhibited by injection-molded shaped article~ of the present lnvention having dimensions of 0.076 x 0.l25 x 3 inches. In a particularly preferred embodiment tensile strength valués of at least 40tO00 psi (~ ~, at least 45,000 psil are exhibited by the injection-molded shaped art1cles of the present inv~ntion having dimensions of 0.076 x 0.125 x 3 inches.
The improved polymer blends of the present invention following injection-molding are capable of exhibiting at least one property selected from the group consisting of tensile strength, tensile modulus, flexural strength and flexural modulus which exceeds that of each of the polymer component~ of the blend when separately injection m~lded. In progressively more preferred embodiments two, three, and all four of such properties of the blend exceed those of each of the polymeric components of the blend when ~eparately injection molded.
Improved melt-extruded three-dimensional articles, such a rods, conveniently can be formed from the polymer blend of the present invention while using standard melt-extrusion .5.L~ 71012-~8 technology. For instance, a preferred mel-t blend of the present invention while at a temperature of approximately 300C. and under a pressure of approximately 100 to 200 psi (e.~., approximate:Ly l50 psi) may be extruded through a circular die having a diameter of 0.125 inch, quenched in water at a temperature of 25C., and taken-up at a rate of approximately 15 to 30 feet per minute.
The physical properties of shaped articles (l.e., three-dimensional articles, etc.) Eormed from the polymer blend of the present invention commonly can be enhanced by subjecting the same to a heat treatment in a non-oxidizing atmosphere, such as that described in -the United States Patent Nos. 3,975,489; 4,189,895; and 4,247,514. In a preferred embodiment the shaped articles are heated in a flowing non-oxidizing atmosphere at a temperature which is approximately 10C. to 30C. below the melting temperature of the polymer blendO Satisfactory residence times for such heat treatment commonly range from approximately 0.5 to approximately 24 hours, or more.
The following examples are presented as specific illustrations oE the claimed invention. It should be understood, however, that the invention is not limited to the specific details set forth in the examples.
EXAMPLE I
A series of five polymer blends (1 e., Blends A
through E) were prepared which differed in the relative concentrations of the wholly aromatic polyester and poly(ester-amide) blend components. Standard injection-molded test bars weLe prepared for each of these blends, as were similarly prepared test bars consisting solely of each of ~he polymer blend components.
The wholly aromatic polyester blend component was prepared in accordance with the teachings of commonly as.~igned United States Patent Mo. 4,161,470, and consisted of 27 mole percent of recurring 6-oxy-2-naphthoyl moieties, and 73 mole percent O.e recurring 4-oxybenzoyl moieties. The wholly aromatic polyester was free of aromatic ring substitut$on, melted when heated to approximately 280C.; exhibited an anisotropic melt phase, was melt-processable above it~ melting temperature, and exhibited an inherent viscosity of approximately 8 dl.~g. when dissolved in a concentration of 0.1 percent by weight in pentafluorophenol at 60C~
Tl~e poly~ester-amide) blend component was prepared in accordance with the teachings of comm~nly assigned United States Patent No. 4,330,457, and consisted of 60 mole percent of recurring 6-oxy-2-naphthoyl moieties, approximately 20 mole percent of recurring terephthaloyl moieties, and approximately 20 mole percent of 4-oxyaminophenylene moieties. The poly(ester-amide) was wholly aromati~ as de~cribed herein, was free of aromatic ring substltution, melted when heated to approximately 2B5C., exhibited an ani~otropic melt phase, wa~ melt~processable above it~ melting temperature, and exhibited an inherent viscosity of approximately 4 dl~/g. when dissolved in a concen-tration of 0.1 percent by weight in pentafluorophenol at 60C.
The five polymer blends ~i.e., Blends A through E) were prepared by melt-blending in a single screw extruder, and were subsequently pelletized. The relative concentrations of each blend component within the polymer blends were as follows:
Wholly Aromatic Wholly Aromatic Blend Polyester Poly(ester-amide) Identification~Percent by weight?(percent by weight) The resulting polymeric blends melted at a temperature in the range of approximately 280 to 290C., and exhibited an anisotropic melt phase.
~ number of standard tes~ bars were prepared by injection-molding each polymer blend using an Arburg molding-machine. A'so, standard test bars similarly were prep~red which were composed solely of each of the polymeric blend components.
The standard test bars used in this Example had a gauge length of one inch, measured 0.076 x 0.125 x 3 inches, and were prepared by injecting the molten polymer blend while at a temperature of 300C. and under a pressure of 4800 psi into molds provided at 100C. while e~ploying a 33 second cycle time~
The tensile properties of the test bars ~i.e., tensile strength, elongation, and t.ensile modulus~ were determined in accordance with the procedure of ASTM D638. The flexural properties of the test bars (i.e., flexural strength and flexural modulus) were determined in accordance with the procedure of AS'~M
D790. The average test results (i.e., an average for 5 bars) are presented below:
s~
Tensil~ Tensile Flexural Fle~ural ~æle 5trength Elcngation Mbdulus 5trength Mbdulus IdrntiEication (psi) _ (peroent~ (psi) __lE~ psi) All ~holly Aromatic 34,343 1.6 3,265,280 32,394 2,115,310 P~ly (ester~mide) Blend A 38,743 1.7 3,536,110 3~694 2,131,940 Blend B 50,988 2.3 3,470,070 361710 2,607,540 Blend C 46,051 2.4 3,108,310 35,237 2,400,520 Blend D 36~572 3~3 2,360,460 25~074 1,531,160 Blend ~ 33,44~ 3.6 2,092,530 22,133 1,269,300 All Wholly Aromatic 33,311 306 2,034,580 20,406 1,167,960 Polyester The surprisingly good mechanical properties exhibited when the blend of the present invention is injection-mold~d are apparent from the foregoing dataO More specifically, for Blends A through D one or more properties selected from the group consisting of terlsile strength, tensile ~nodulus, flexural strength, and flexural modulus exceeded those exhibited by each of the components o~ the polymeric blend when ~eparately injection-molded.
EXAMPLE II
~ xample ~ was substantially repeated with the exception that the standard test bar~ for~ed had a gauge length of two inches, and were of a larger configuration which measured 0.125 xØ5 x 5 inches. Such test bars together with appropriate controls were formed using a Windsor molding-machine and in some instances incorporated chopped glass fibers as reinforcement (as described).
Wholly Arcmatic Wholly Aromatic C~d ~ le Polyester PDl~(ester-amide) Glass Fibers Identification ~ O~et~ Y~ IE~ Y~9~1 F 100 0 o Blend G 30 70 0 . ~ ' O 100 0 Blend J 30 70 Blend M 30 70 50 The tensile properties of the test bars (i.e. t tensile strength, elongation/ and ten~ile modulus) were determined in accordance with the procedure of ASTM D638. The flexural properties of the test bars ~i e., flexural strength and flexural modulus) were determined in ac~ordance with the procedure of ASTM
D790. The average test results (i.e. an average of 5 bars) are presented below:
, Tensile Tensile Flexural Fle~ural ~le Strength ~1cngation ~kdulU5 Stre~gth ~bdulus Identificat~on si) ~cent) ~p~) (psi) ~Fsi) F 24,500 4.0 1,390,000 22,2Q0 1,310,000 Blend G 37,300 1.5 3,130,000 37,200 2,570lO00 H 27,300 1.3 2,790,000 35,600 2,220,000 I 28,800 2.2 2,390,000 35,900 2,000~000 Blend J 37,300 1.4 3,830,000 46,300 3,110,000 P~ 33,400 1.2 3,500,000 43,800 3,390,000 L 26,600 1.2 3,400,000 .34,600 2,730,000 Blend M 33,400 1.1 4,100,000 41,900 3,610,000 N 25,600 0.8 3,640,000 39,300 3,390~000 The ~urpr~singly good mechanical properties exhibited when a glas~ filled blend of the present invention i5 injection-molded are ~ipparent from the foregoing data. More specifically, for Blends G, J, and M at least three of the properties selected ~rom the group consisting of ten~ile strength, tensile modulus, flexural strength, and flexural modulus exceeded those exhiblted by each of components of the polymer blend when separately injection-molded. Such result was obtained in Blends J and M
even in the presence of glass fiber reinforce~ent.
-2~-EXAMPLE III
A polymer blend substantially similar that Blend B of Example I was selected for melt-extrusion to form an elongated circular rod. The polymer blend consisted of 30 percent by weight of the wholly aromatic polyester and 70 percent by weight of the poly(ester-amide).
While at a temperature oE 280C., the molten polymer blend of the present invent;on was melt-extruded while under a pressure of 150 psi through a circular die having a 4Ua~ of Q.125 inch. ~ollowing extrusion the resulting extrudate was quenched in a water bath provided at 25C. and was taken-up at a rate of 20 feet per minute. The resulting circular rod had a diameter of 0.075 inch and was tested to determine its tensile ,~:
modulus. It: was found that an average tensile modulus of 7,700,000 psi was exh;bited.
For comparative purposes this Example was repeated with the exception that each of the polymeric blend components were similarly melt~extruded and the resulting rod products were evaluated. It was found that the resulting circular rod formed from the wholly aromatic polyester exhibited an average tensile modulus of 3,000,000 psi, and the resulting rod formed from the polytester-amide) exhibited an average tensile modulu~ of 6,000,00~ psi.
Although the invention ha~ been descrlbed with preferred embodiments, it is to be understood that variations and modifications may be employed without departing from the concept - of the invention a~ defined in the follo~ing claim~:
~, ,
~ ~, by end group determination via infrared spectroscopy on compression molded films). Alternatively, light scattering techniques in a penta~luorophenol solution may be employed to determine the molecular weight.
The melt-processable wholly aromatic polyester which serves as the first component oE the polymer blend commonly exhibits an inherent viscosity (i.e. I.V.) of at least approxim~tely 2.0 dl./g. (e.g., approximately 2.0 to 12.0 cll./g.) when dissolved in a concentration of 0.1 percent by weight in pentafluorophenol at 60C.
In a preferred embodiment of the present invention the melt-processable wholly aromatic polyester is that of commonly assigned United States Patent No. 4,161,470. In such embodiment the melt-processable wholly aromatic polyester consists essentially of moieties I and II which may include suhstitution of at least some of the hydrogen atoms present upon an aromatic ring wherein:
I is ~ c , and ~
II is ~ ~-with said optional substitution if present being selected from ~ 20 the group consisting oE an alkyl group o~ 1 to 4 carbon atoms, an alkoxy group of 1 to 4 carbon atoms, halogen, phenyl, and mixtures thereof, and wherein said wholly aromatic polyester comprises approximately 10 to 90 mole percent of moeity I and approximately 10 to 90 mole percent of moiety II. In a preferred embodment the aromatic rings of the wholly aromatic polyester are substantially free of ring sub~titution. Also, in a preferred embodiment the wholly aromatic polye~ter compri~es approximately 15 to 35 mole percent of moiety I and approximately 65 to as mole percent of moiety II. In a particularly preferred embodi~ent the wholly aromatic polyester consists essentially of approximately 27 mole percent of recurring 6-oxy-2-naphthoyl moieties and approximately 73 mole percent of recurring 4-oxybenzoyl moieties.
The second component of the polymer blend of the present invention i~ a melt-processable poly(ester-amide) which is capable of formlng an anisotropic melt phase. Such polymer also is melt-processable in the sense that it exhibits a melting ~emperature below its decomposition or degradation temperature and can be satisfactorily injection-molded or melt-extruded to form shaped articles apart from the blend of the present invention. Such poly(ester-amide) preferably i~ wholly aromatic in the sense that each monomer which i5 polymerized to form the polymer backbone contribute~ at least one aromatic ring. The anisotropic character of the melt phase can be confirmed as discussed with respect to the wholly aromatic polyester blend component~
The anisotropic melt-forming poly(ester-amides) which can serve as the second component in the polymer blend of the present invention are al50 known to tho~e skilled in polymer technology~ Such poly(ester-amides) are also generally prepared from monomers which are long, flat and fairly rigid along the long axis of the molecules and commonly have chain-extending 71012-4~
5~i linkages that are nei-ther coaxial or parallel. The reactive moieties untili~ed to form the poly(ester-amides) commonly are aromatic amines, aromatic diols, aromatlc or cyclohexylene diacids, and aromatic hydroxyacids, or their derivatives. The aromatic rings included in the polymer chains may optionally include substitution as previously described in conjunction with the wholly aromatic polyester blend component.
Representa-tive melt-processable aniso-tropic melt-forming poly(ester-amides) which may be selected to service as the second component of the polymer blend are disclosed in Uni-ted States Patent Nos. 4,272,625; 4,330,457; 4,339,376;
4,341,688; 4,351,917; 4,351,918; and 4,355,132.
The poly(ester-amide) blend component generally may be formed by the same polymerization routes described in con-junction with the wholly aromatic polyester blend component with amine reactive monomer groups (or amine derivatives) being substituted in whole or in part for hydroxyl reactive monomer groups (or their derivatives).
The melt-processable poly(ester-amides) capable of ~0 Eorming the second component of the polymer blend also tend to be subs-tantially insoluble in common solvents and accordingly are not susceptible -to solution processing. As discussed previously, they can be reaclily processed by common melt-processing techniques. ~ost suitable poly(ester-amides) are soluable in pen-tafluorophenol to a limi-ted degree.
The melt-processable poly(ester-amides) commonly exhibit a weiyht average molecular weight of about 2,000 to 200,000, and preferably about 10,000 to 50,000, and most ".~
~2~ 710~2-~8 perferably about 20,000 to 25,000. Such molecular weiyhts can be determined as described in conjunction with the wholly aromatic polyester blend component.
The melt~processable poly(ester-amide) which serves as the second co~lponent of the polymer blend commonly exhibits an inherent viscosity (i~e., I.V.) of at least approximately 2.0 dl./g. (e.g., approximately 2.0 to 12.0 dl./g.) when dissolved in a concentration of 0.1 percent by weight in pentafluorophenol at 60C. In a particularly preferred embodiment the poly(ester-amide) blend component exhibits and inherent viscosity of approximately 3 to 6 dl./g. when examined via such I.V. determination.
In a preferred embodiment of the present invention the melt-processable poly(ester-amide) is that of commonly assigned United States Patent No. 4,330,457. In such embodiment the melt-processable poly(ester-amide) consists essentially of moieties I, II, III, and optionally IV, wherein:
I is ~ ~~
O O
II is- C - A - C -, ~ 20 where A is a divalent radical comprising at least one aromatic ring or a divalent trans-l,~-cyclohexylene radical, III is - Y - Ar - Z - where Ar is a divalent radical comprising at least one aromatic ring, Y is 0, NH
or NR, and Z i8 NH or NR, where R is an alkyl group of l to 6 ~arbon atoms; and IV i~ - 0 - Ar' - 0 - where Ar' i~ a divalent radical comprising at least one aromatic ring;
wherein at least some of the hydrogen atoms present upon the rings optionally may be replaced by substitution selected from the group consisting of an alkyl group of l to 4 carbon atoms, an alkoxy group of l to 4 carbon atom~, halogen, phenyl, and mixtures thereof, and wherein said poly(ester-amide~ comprises approximately lO to 90 mole percent of moiety I, approximately 5 to 45 mole percent of moiety II, appro~imately 5 to 45 ~ole percent of moiety III, and approximately 0 to 40 mole percent of moiety IV~ In a preferred embodiment the aromatic rings of the poly(ester-amide) are substantially free of ring substitution.
Also, in a preferred embodiment the poly~ester-amide) i~ wholly aromatic.in the sense that each monomer which is polymerized to form the polymer contributes at least one aromatic ring.
Addi~ionally, in a preferred embodiment the poly(ester-amide) comprises approximately 40 to 80 mole percent of moiety I, approximately 5 to 30 mole percent of moiety II, approxim~tely 5 to 30 ~ole percent of moiety III, and approximately 0 to 40 mole percent of moiety IV. In a particularly preferred embodiment the poly~ester-amide) conslsts essentially of approximately 60 mole percent of recurring 6-oxy-2-naphthoyl moieties, appro~imately 20 mole percent of recurring terephthaloyl moieties, and approximately 20 ~ole percent of 4-oxyaminophenylene moieties.
The polymer blend of the present invention has been found to be morphologically homogeneous in that when an exposed surface of a broken test ~pecimen formed from the same is examined by scanning electron microscopy at a magnification of 2000X, no dlscrete domains of each polymeric component are apparent. Also, the polymer blend of the pxesent invention commonly has been found to exhibit unusually low melt viscosity values. Such melt viscosity at low shear rates typically is lower than that of each of the polymeric blend components. For instance, a representative wholly aromatic polyester of U.S.
Patent ~o. 4,1~1,470 was found to exhibit a melt viscosity of approximately 4788 poise at a shear rate of 10 secO 1~ and a representative poly(ester-amide) of ~.S. Patent No. 4,330,457 was found to exhibit a melt viscosity of appro~imately 5737 pols~ at a shear rat~ of 10 sec.~l. When 70 percent by weight of the wholly aromatic polyester was melt blended with 30 percent by weight of the poly~ester-amide~, the blend melt visco~ity dropped to appro~imately 4301 poise at a shear rate of 10 sec. 1.
Additlonally, when 30 percent by weight of the wholly aromatic.
polyester was melt blended with 70 percent by weight of the poly(e~ter-amide), the blend melt vi~cosity dropped even urther to approximately 2fiO6 poise at a shear rate of 10 sec. 1.
~ he polymer blend of the present invention comprises appro~imately 5 to approximately 95 percent by weight of the wholly aromatic polyester and approximately 5 to 95 percent by weight of the poly~ester-amide) based upon the total weight of these components. ~or~ spe~ifically~ the polymer blend may comprise approximately 20 to approxlmately 80 percent by weight of the wholly aromatic polyester and approximately 20 to approximately 80 percen~ by weight of the poly(ester-amide) based upon the total weight of these components. In a more preferred embodiment o the present invention the polymer blend comprises approxima~ely 25 to approximately 75 percent by weight of the wholly aromatic polyester and approximately 25 to approximately 75 percent by weight of the poly(ester-amide) based upon the Cor~ n,~ 5 total weight of these 44~pe~e~. In a particularly preferred embodiment the polymer blend comprises approximately 30 percent by weight of the wholly aromatic polyester and approximately 70 percent by weight of the poly(ester-amide3. ~ach of the above weight percentages for the polymeric components of the blend is exclusive of additionally added components, such as reinforcing agents, fillers, etc., which are discussed hereafter.
The polymer blend of the present invention may optionally Lncorporate approximately 1 to approximately 60 percent by weigh~ (preferably approximately 10 to 30 percent by weight), based upon the total weight of the molding composition, i of a solid filler and/or reinforcing agent. Representative filler materials include calcium silicate, silica, clays, talc, mica, poly~etrafluoroethylene, graphite, alumina trihydrate, sodium aluminum carbonate, barium ferrite, etc. Representative reinforcing fibers include glass fibers, asbestos, graphitic carbon fibers, amorphou~ carbon fibers, synthetic polymeric fiber~, alumina fiberst aluminum silicate fibers, alu~inum oxide fibers, titanium fibers, ~agnesium fibers, rock wool fibers, steel fiber~ tungsten fiber-~, cotton, wool, wood cellulose fibers, ets~ The relatively low melt viscosity of th~ polymeric blend enables substantLal concentrations of a solid filler and/or reinforcing agent to be added without rai~ing the melt viscosity to unacceptably high levels.
The improved polymer blend of the present invention is formed by mixing the wholly aromatis polyester and poly(ester-amide) components while each i~ in the Molten ~tate. For instance, lnitially the polymeric component~ can be individually provided in the form of solid chips or pellets ~ach of the components can be separately we~ghed, and then physically mixed together in an appropriate apparatus (~ a ball mill). If a solid filler and/or reinforcing agent is to be incorporated within the polymer blend, it too can be physically admixed with the solid polymer components at this point in time. The physical admixture of the solid polymeric blend components preferably is next dried. Such drying convenien~ly can be conducted in a vacuum oven or in a circulating air oven, although any suitable apparatus may be usedO The purpose of the drying step is to remove water from the physical mixture so as to prevent water-initiated degradation of the polymers during the melt-blending operation. After the mixture of solid polymer particles has been dried, a substantially uniform polymer melt blend can then be prepared. A convenient method for forming the polymer ~elt bl~nd 1~ by melt-extrusion. The extrusion apparatu~ thoroughly mixes the polymers in the melt and then extrudes the blend in the form of a strand which upon solidification can be cut or broken into cbips or pellets which are suitable to form improved shaped articles. Alternatively, discrete pellets of each of the polymer blend components can be fed to the hopper of an injection-molding machine with the desired melt-blending being accomplished by the plasticating action of the screw of the injection-molding machine.
~6~5~L5i The polymer blend of the present invention commonly is capable of being melt-processed at a temperature in the range of approximately 250C, to 400C. In a preferred embodiment of the present invention the polymer blend is capable of being melt processed at a temperature in the range of approximately'260C.
to 350C. In a more preferred embodiment of the present invention, the polymer blend is capable of being melt-processed at a temperature in the range of approximately 280C. to 330C.
In the most preferred embodiment of the present invention the polymer blend is capable of being melt-processed at a temperature in the range of approximately 2~0C. to 300C.
It has been found that the polymer blend of the present invention can be used to form shaped articles which have surprisingly outstanding mechanical properties while using conventiona, shaped article~forming techniques. Such shaped articles can be in the configuration of improved molded articles ~i.e., three-dimensional molded articles), improved melt-extruded three-dimensional articles (~ ~, rods or pipes), etc.
Shaped three-dlmensional articles can be formed from the polymer blend of the present invention while using injection-molding technology. For instance, a preferred molten melt blend of the present invention while at a temperature of approximately 300Co and under a pressure of approximately 1,000 to 20,000 psi (e.g., approximately 3,000 to 10,000 psi) may be injected into a mold cavity. The mold cavity commonly is maintained at a temperature of approximately 25 to 150C. (~ , approximately lG0C.). The cycle time (i.e., the time between injections) for the polymer blend commonly is approximately 10 to 120 seconds.
When standard test bars are formea by injection-molding the polymer blend oE the present invention and are tested, they are found to exhibit surprisingly outstanding mechanical proper-ties. The standard test bars can possess dimensions of 0u076 x .125 x 3 inches (one inch gauge length) or 0.125 x 0.5 x 5 inches (two inch gauge length) and their tensile strength and tensile modulus values can be determined in accordanc~ with the standard ASTM D638 procedure~ The flexural properties of the test bars (i.e.~ flexural strength and flexural modulus) can be determined in a~cordance with the procedure of ASTM D790.
Tensile strength values of at least 35,000 psi preferably are exhibited by injection-molded shaped article~ of the present lnvention having dimensions of 0.076 x 0.l25 x 3 inches. In a particularly preferred embodiment tensile strength valués of at least 40tO00 psi (~ ~, at least 45,000 psil are exhibited by the injection-molded shaped art1cles of the present inv~ntion having dimensions of 0.076 x 0.125 x 3 inches.
The improved polymer blends of the present invention following injection-molding are capable of exhibiting at least one property selected from the group consisting of tensile strength, tensile modulus, flexural strength and flexural modulus which exceeds that of each of the polymer component~ of the blend when separately injection m~lded. In progressively more preferred embodiments two, three, and all four of such properties of the blend exceed those of each of the polymeric components of the blend when ~eparately injection molded.
Improved melt-extruded three-dimensional articles, such a rods, conveniently can be formed from the polymer blend of the present invention while using standard melt-extrusion .5.L~ 71012-~8 technology. For instance, a preferred mel-t blend of the present invention while at a temperature of approximately 300C. and under a pressure of approximately 100 to 200 psi (e.~., approximate:Ly l50 psi) may be extruded through a circular die having a diameter of 0.125 inch, quenched in water at a temperature of 25C., and taken-up at a rate of approximately 15 to 30 feet per minute.
The physical properties of shaped articles (l.e., three-dimensional articles, etc.) Eormed from the polymer blend of the present invention commonly can be enhanced by subjecting the same to a heat treatment in a non-oxidizing atmosphere, such as that described in -the United States Patent Nos. 3,975,489; 4,189,895; and 4,247,514. In a preferred embodiment the shaped articles are heated in a flowing non-oxidizing atmosphere at a temperature which is approximately 10C. to 30C. below the melting temperature of the polymer blendO Satisfactory residence times for such heat treatment commonly range from approximately 0.5 to approximately 24 hours, or more.
The following examples are presented as specific illustrations oE the claimed invention. It should be understood, however, that the invention is not limited to the specific details set forth in the examples.
EXAMPLE I
A series of five polymer blends (1 e., Blends A
through E) were prepared which differed in the relative concentrations of the wholly aromatic polyester and poly(ester-amide) blend components. Standard injection-molded test bars weLe prepared for each of these blends, as were similarly prepared test bars consisting solely of each of ~he polymer blend components.
The wholly aromatic polyester blend component was prepared in accordance with the teachings of commonly as.~igned United States Patent Mo. 4,161,470, and consisted of 27 mole percent of recurring 6-oxy-2-naphthoyl moieties, and 73 mole percent O.e recurring 4-oxybenzoyl moieties. The wholly aromatic polyester was free of aromatic ring substitut$on, melted when heated to approximately 280C.; exhibited an anisotropic melt phase, was melt-processable above it~ melting temperature, and exhibited an inherent viscosity of approximately 8 dl.~g. when dissolved in a concentration of 0.1 percent by weight in pentafluorophenol at 60C~
Tl~e poly~ester-amide) blend component was prepared in accordance with the teachings of comm~nly assigned United States Patent No. 4,330,457, and consisted of 60 mole percent of recurring 6-oxy-2-naphthoyl moieties, approximately 20 mole percent of recurring terephthaloyl moieties, and approximately 20 mole percent of 4-oxyaminophenylene moieties. The poly(ester-amide) was wholly aromati~ as de~cribed herein, was free of aromatic ring substltution, melted when heated to approximately 2B5C., exhibited an ani~otropic melt phase, wa~ melt~processable above it~ melting temperature, and exhibited an inherent viscosity of approximately 4 dl~/g. when dissolved in a concen-tration of 0.1 percent by weight in pentafluorophenol at 60C.
The five polymer blends ~i.e., Blends A through E) were prepared by melt-blending in a single screw extruder, and were subsequently pelletized. The relative concentrations of each blend component within the polymer blends were as follows:
Wholly Aromatic Wholly Aromatic Blend Polyester Poly(ester-amide) Identification~Percent by weight?(percent by weight) The resulting polymeric blends melted at a temperature in the range of approximately 280 to 290C., and exhibited an anisotropic melt phase.
~ number of standard tes~ bars were prepared by injection-molding each polymer blend using an Arburg molding-machine. A'so, standard test bars similarly were prep~red which were composed solely of each of the polymeric blend components.
The standard test bars used in this Example had a gauge length of one inch, measured 0.076 x 0.125 x 3 inches, and were prepared by injecting the molten polymer blend while at a temperature of 300C. and under a pressure of 4800 psi into molds provided at 100C. while e~ploying a 33 second cycle time~
The tensile properties of the test bars ~i.e., tensile strength, elongation, and t.ensile modulus~ were determined in accordance with the procedure of ASTM D638. The flexural properties of the test bars (i.e., flexural strength and flexural modulus) were determined in accordance with the procedure of AS'~M
D790. The average test results (i.e., an average for 5 bars) are presented below:
s~
Tensil~ Tensile Flexural Fle~ural ~æle 5trength Elcngation Mbdulus 5trength Mbdulus IdrntiEication (psi) _ (peroent~ (psi) __lE~ psi) All ~holly Aromatic 34,343 1.6 3,265,280 32,394 2,115,310 P~ly (ester~mide) Blend A 38,743 1.7 3,536,110 3~694 2,131,940 Blend B 50,988 2.3 3,470,070 361710 2,607,540 Blend C 46,051 2.4 3,108,310 35,237 2,400,520 Blend D 36~572 3~3 2,360,460 25~074 1,531,160 Blend ~ 33,44~ 3.6 2,092,530 22,133 1,269,300 All Wholly Aromatic 33,311 306 2,034,580 20,406 1,167,960 Polyester The surprisingly good mechanical properties exhibited when the blend of the present invention is injection-mold~d are apparent from the foregoing dataO More specifically, for Blends A through D one or more properties selected from the group consisting of terlsile strength, tensile ~nodulus, flexural strength, and flexural modulus exceeded those exhibited by each of the components o~ the polymeric blend when ~eparately injection-molded.
EXAMPLE II
~ xample ~ was substantially repeated with the exception that the standard test bar~ for~ed had a gauge length of two inches, and were of a larger configuration which measured 0.125 xØ5 x 5 inches. Such test bars together with appropriate controls were formed using a Windsor molding-machine and in some instances incorporated chopped glass fibers as reinforcement (as described).
Wholly Arcmatic Wholly Aromatic C~d ~ le Polyester PDl~(ester-amide) Glass Fibers Identification ~ O~et~ Y~ IE~ Y~9~1 F 100 0 o Blend G 30 70 0 . ~ ' O 100 0 Blend J 30 70 Blend M 30 70 50 The tensile properties of the test bars (i.e. t tensile strength, elongation/ and ten~ile modulus) were determined in accordance with the procedure of ASTM D638. The flexural properties of the test bars ~i e., flexural strength and flexural modulus) were determined in ac~ordance with the procedure of ASTM
D790. The average test results (i.e. an average of 5 bars) are presented below:
, Tensile Tensile Flexural Fle~ural ~le Strength ~1cngation ~kdulU5 Stre~gth ~bdulus Identificat~on si) ~cent) ~p~) (psi) ~Fsi) F 24,500 4.0 1,390,000 22,2Q0 1,310,000 Blend G 37,300 1.5 3,130,000 37,200 2,570lO00 H 27,300 1.3 2,790,000 35,600 2,220,000 I 28,800 2.2 2,390,000 35,900 2,000~000 Blend J 37,300 1.4 3,830,000 46,300 3,110,000 P~ 33,400 1.2 3,500,000 43,800 3,390,000 L 26,600 1.2 3,400,000 .34,600 2,730,000 Blend M 33,400 1.1 4,100,000 41,900 3,610,000 N 25,600 0.8 3,640,000 39,300 3,390~000 The ~urpr~singly good mechanical properties exhibited when a glas~ filled blend of the present invention i5 injection-molded are ~ipparent from the foregoing data. More specifically, for Blends G, J, and M at least three of the properties selected ~rom the group consisting of ten~ile strength, tensile modulus, flexural strength, and flexural modulus exceeded those exhiblted by each of components of the polymer blend when separately injection-molded. Such result was obtained in Blends J and M
even in the presence of glass fiber reinforce~ent.
-2~-EXAMPLE III
A polymer blend substantially similar that Blend B of Example I was selected for melt-extrusion to form an elongated circular rod. The polymer blend consisted of 30 percent by weight of the wholly aromatic polyester and 70 percent by weight of the poly(ester-amide).
While at a temperature oE 280C., the molten polymer blend of the present invent;on was melt-extruded while under a pressure of 150 psi through a circular die having a 4Ua~ of Q.125 inch. ~ollowing extrusion the resulting extrudate was quenched in a water bath provided at 25C. and was taken-up at a rate of 20 feet per minute. The resulting circular rod had a diameter of 0.075 inch and was tested to determine its tensile ,~:
modulus. It: was found that an average tensile modulus of 7,700,000 psi was exh;bited.
For comparative purposes this Example was repeated with the exception that each of the polymeric blend components were similarly melt~extruded and the resulting rod products were evaluated. It was found that the resulting circular rod formed from the wholly aromatic polyester exhibited an average tensile modulus of 3,000,000 psi, and the resulting rod formed from the polytester-amide) exhibited an average tensile modulu~ of 6,000,00~ psi.
Although the invention ha~ been descrlbed with preferred embodiments, it is to be understood that variations and modifications may be employed without departing from the concept - of the invention a~ defined in the follo~ing claim~:
~, ,
Claims (55)
1. A polymer blend formed by melt-mixing which when molten is capable of exhibiting an anistropic melt phase and which following injection-molding is capable of exhibiting at least one property selected from the group consisting of tensile strength, tensile modulus, flexural strength, and flexural modulus, which exceeds that of each of the polymeric components of the blend when separately injection-molded comprising:
(a) approximately 5 to approximately 95 percent by weight, based upon the total weight of components (a) and (b), of a melt-processable wholly aromatic polyester which is capable of forming an anisotropic melt phase and which is substantially free of amide linkages; and (b) approximately 5 to approximately 95 percent by weight, based upon the total weight of components (a) and (b), of a melt-processable poly(ester-amide) which is capable of forming an anisotropic melt phase.
(a) approximately 5 to approximately 95 percent by weight, based upon the total weight of components (a) and (b), of a melt-processable wholly aromatic polyester which is capable of forming an anisotropic melt phase and which is substantially free of amide linkages; and (b) approximately 5 to approximately 95 percent by weight, based upon the total weight of components (a) and (b), of a melt-processable poly(ester-amide) which is capable of forming an anisotropic melt phase.
2. A polymer blend according to Claim 1 which is capable of being melt-processed at a temperature in the range of approximately 250°C. to 400°C.
3. A polymer blend according to Claim 1 which in capable of being melt-processed at a temperature in the range of approximately 260°C. to 350°C.
4. A polymer blend according to Claim 1 which is capable of being melt-processed at a temperature in the range of approximately 280°C. to 330°C.
5. A polymer blend according to Claim 1 which following injection-molding is capable of exhibiting at least two properties selected from the group consisting of tensile strength, tensile modulus, flexural strength, and flexural modulus which exceed those of each of the polymeric components of the blend when separately injection-molded.
6. A polymer blend according to Claim 1 which following injection-molding is capable of exhibiting at least three properties selected from the group consisting of tensile strength, tensile modulus, flexural strength, and flexural modulus which exceed those of each of the polymeric components of the blend when separately injection-molded.
7. A polymer blend according to Claim 1 which following injection-molding is capable of exhibiting a tensile strength, tensile modulus, flexural strength, and flexural modulus which exceed those of each of the polymeric components of the blend when separately injection molded.
8. A polymer blend according to Claim 1 wherein polymer components (a) and (b) each exhibit an inherent viscosity of at least 2.0 dl./g. when dissolved in a concentration of 0.1 percent by weight in pentafluorophenol at 60°C.
9. A polymer blend according to Claim 1 which comprises approximately 20 to approximately 80 percent by weight of component (a), based upon the total weight of components (a) and (b), and approximately 20 to approximately 80 percent by weight of component (b), based upon the total weight of components (a) and (b).
10. A polymer blend according to Claim 1 which comprises approximately 25 to approximately 75 percent by weight of component (a), based upon the total weight of components (a) and (b), and approximately 25 to approximately 75 percent by weight of component (b) based upon the total weight of components (a) and (b).
11. A polymer blend according to Claim 1 which comprises approximately 30 percent by weight of component (a), based upon the total weight of components (a) and (b), and approximately 70 percent by weight of component (b), based upon the total weight of components (a) and (b).
12. A polymer blend according to Claim 1 wherein component (a) is a melt-processable wholly aromatic polyester and consists essentially of moieties I and II which may include substitution of at least some of the hydrogen atoms present upon an aromatic ring wherein:
I is , and II is , with said optional substitution if present being selected from the group consisting of an alkyl group to 1 to 4 carbon atoms, an alkoxy group of 1 to 4 carbon atoms, halogen, phenyl, and mixtures thereof, and wherein said wholly aromatic polyester comprises approximately 10 to 90 mole percent of moiety I and approximately 10 to 90 mole percent of moiety II.
I is , and II is , with said optional substitution if present being selected from the group consisting of an alkyl group to 1 to 4 carbon atoms, an alkoxy group of 1 to 4 carbon atoms, halogen, phenyl, and mixtures thereof, and wherein said wholly aromatic polyester comprises approximately 10 to 90 mole percent of moiety I and approximately 10 to 90 mole percent of moiety II.
13. A polymer blend according to Claim 1 wherein component (b) is a melt-processable poly(ester-amide) and consists essentially of moieties I, II, III, and optionally IV, wherein:
I is ;
II is where A is a divalent radical comprising at least one aromatic ring or a divalent trans-1,4-cyclohexylene radical;
III is - Y - Ar - Z - where Ar is a divalent radical comprising at least one aromatic ring, Y is 0, NH
or NR, and Z is NH or NR, where R is an alkyl group of 1 to 6 carbon atoms; and IV is - O - Ar' - O - where Ar' is a divalent radical comprising at least one aromatic ring;
wherein at least some of the hydrogen atoms present upon the rings optionally may be replaced by substitution selected from the group consisting of an alkyl group of 1 to 4 carbon atoms, an alkoxy group of 1 to 4 carbon atoms, halogen, phenyl, and mixtures thereof, and wherein said poly(ester-amide) comprises approximately 10 to 90 mole percent of moiety I, approximately 5 to 45 mole percent of moiety II, approximately 5 to 45 mole percent of moiety III, and approximately 0 to 40 mole percent of moiety IV.
I is ;
II is where A is a divalent radical comprising at least one aromatic ring or a divalent trans-1,4-cyclohexylene radical;
III is - Y - Ar - Z - where Ar is a divalent radical comprising at least one aromatic ring, Y is 0, NH
or NR, and Z is NH or NR, where R is an alkyl group of 1 to 6 carbon atoms; and IV is - O - Ar' - O - where Ar' is a divalent radical comprising at least one aromatic ring;
wherein at least some of the hydrogen atoms present upon the rings optionally may be replaced by substitution selected from the group consisting of an alkyl group of 1 to 4 carbon atoms, an alkoxy group of 1 to 4 carbon atoms, halogen, phenyl, and mixtures thereof, and wherein said poly(ester-amide) comprises approximately 10 to 90 mole percent of moiety I, approximately 5 to 45 mole percent of moiety II, approximately 5 to 45 mole percent of moiety III, and approximately 0 to 40 mole percent of moiety IV.
14. A polymer blend according to Claim 1 wherein the aromatic rings of the polymeric components are substantially free of ring substitution.
15. A polymer blend according to Claim 1 which following injection-molding is capable of exhibiting a tensile strength of at least 35,000 psi.
16. A polymer blend according to Claim 1 which following injection-molding is capable of exhibiting a tensile strength of at least 40,000 psi.
17. A polymer blend according to Claim 1 which following injection-molding is capable of exhibiting a tensile strength of at leat 45,000 psi.
18. A molding compound comprising the polymer blend of Claim 1 which incorporates approximately 1 to approximately 60 percent by weight, based upon the total weight of the molding compound, of a solid filler and/or reinforcing agent.
19. A molded article comprising the polymer blend of Claim 1.
20. A melt-extruded three-dimensional article comprising the polymer blend of Claim 1.
21. A shaped article comprising the polymer blend of Claim 1 which has been subjected to heat treatment in a non-oxidizing atmosphere at approximately 10°C. to 30°C. below the melting temperature of the blend.
22. A polymer blend formed by melt-mixing which when molten is capable of exhibiting an anisotropic melt phase and which following injection-molding is capable of exhibiting at least one property selected from the group consisting of tensile strength, tensile modulus, flexural strength, and flexural modulus which exceeds that of each of the polymeric components of the blend when separately injection molded comprising:
(a) approximately 5 to approximately 95 percent by weight, based upon the total weight of components (a) and (b), of a melt-processable wholly aromatic polyester which is capable of forming an aniso-tropic melt phase and which is substantially free of amide linkages and which consists essentially of moieties I and II which may include substitution of at least some of the hydrogen atoms present upon an aromatic ring wherein:
I is , and II is , with said optional substitution if present being selected from the group consisting of an alkyl group of 1 to 4 carbon atoms, an alkoxy group of 1 to 4 carbon atoms, hydrogen, phenyl, and mixtures thereof, wherein said melt-processable wholly aromatic polyester comprises approximately 10 to 90 mole percent of moiety I and approximately 10 to 90 mole percent of moiety II, and (b) approximately 5 to approximately 95 percent by weight, based upon the total weight of components (a) and (b), of a melt-processable poly(ester-amide) which is capable of forming an anisotropic melt phase which consists essentially of moieties I, II, III, and optionally, IV wherein:
I is ;
II is where A is a divalent radical comprising at least one aromatic ring or a divalent trans-1,4-cyclohexylene radical;
III is - Y - Ar - Z - where Ar is a divalent radical comprising at least one aromatic ring, Y is O, NH or NR and Z is NH or NR, where R is an alkyl group of 1 to 6 carbon atoms; and IV is - O - Ar' - O - where Ar' is a divalent radical comprising at least one aromatic ring;
wherein at least some of the hydrogen atoms present upon the rings optionally may be replaced by substitution selected from the group consisting of an alkyl group of 1 to 4 carbon atoms, an alkoxy group of 1 to 4 carbon atoms, halogen, phenyl, and mixtures thereof, and wherein said poly(ester-amide) comprises approximately 10 to 90 mole percent of moiety I, approximately 5 to 45 mole percent of moiety II, approximately 5 to 45 mole percent of moiety III, and approximately 0 to 40 mole percent of moiety IV.
(a) approximately 5 to approximately 95 percent by weight, based upon the total weight of components (a) and (b), of a melt-processable wholly aromatic polyester which is capable of forming an aniso-tropic melt phase and which is substantially free of amide linkages and which consists essentially of moieties I and II which may include substitution of at least some of the hydrogen atoms present upon an aromatic ring wherein:
I is , and II is , with said optional substitution if present being selected from the group consisting of an alkyl group of 1 to 4 carbon atoms, an alkoxy group of 1 to 4 carbon atoms, hydrogen, phenyl, and mixtures thereof, wherein said melt-processable wholly aromatic polyester comprises approximately 10 to 90 mole percent of moiety I and approximately 10 to 90 mole percent of moiety II, and (b) approximately 5 to approximately 95 percent by weight, based upon the total weight of components (a) and (b), of a melt-processable poly(ester-amide) which is capable of forming an anisotropic melt phase which consists essentially of moieties I, II, III, and optionally, IV wherein:
I is ;
II is where A is a divalent radical comprising at least one aromatic ring or a divalent trans-1,4-cyclohexylene radical;
III is - Y - Ar - Z - where Ar is a divalent radical comprising at least one aromatic ring, Y is O, NH or NR and Z is NH or NR, where R is an alkyl group of 1 to 6 carbon atoms; and IV is - O - Ar' - O - where Ar' is a divalent radical comprising at least one aromatic ring;
wherein at least some of the hydrogen atoms present upon the rings optionally may be replaced by substitution selected from the group consisting of an alkyl group of 1 to 4 carbon atoms, an alkoxy group of 1 to 4 carbon atoms, halogen, phenyl, and mixtures thereof, and wherein said poly(ester-amide) comprises approximately 10 to 90 mole percent of moiety I, approximately 5 to 45 mole percent of moiety II, approximately 5 to 45 mole percent of moiety III, and approximately 0 to 40 mole percent of moiety IV.
23. A polymer blend according to Claim 22 which is capable of being melt-processed at a temperature in the range of approximately 250°C. to 400°C.
24. A polymer blend according to Claim 22 which is capable of being melt-processed at a temperature in the range of approximately 260°C. to 350°C.
25. A polymer blend according to Claim 22 which is capable of being melt-processed at a temperature in the range of approximately 280°C. to 330°C.
26. A polymer blend according to Claim 22 which following injection-molding is capable of exhibiting at least two properties selected from the group consisting of tensile strength, tensile modulus, flexural strength, and flexural modulus which exceed those of each of the polymeric components of the blend when separately injection-molded.
27. A polymer blend according to Claim 22 which following injection-molding is capable of exhibiting at least three properties selected from the group consisting of tensile strength, tensile modulus, flexural strength, and flexural modulus which exceed those of each of the polymeric components of the blend when separately injection-molded.
28. A polymer blend according to Claim 22 which following injection-molding is capable of exhibiting a tensile strength, tensile modulus, flexural strength, and flexural modulus which exceed those of each of the polymeric components of the blend when separately injection-molded.
29. A polymer blend according to Claim 22 wherein polymer components (a) and (b) each exhibit an inherent viscosity of at least 2.0 dl./g. when dissolved in a concentration of 0.1 percent by weight in pentafluorophenol at 60°C.
30. A polymer blend according to Claim 22 which comprises approximately 20 to approximately 80 percent by weight of component (a), based upon the total weight of components (a) and (b), and approximately 20 to approximately 80 percent by weight of component (b), based upon the total weight of .
components (a) and (b).
components (a) and (b).
31. A polymer blend according to Claim 22 which comprises approximately 25 to approximately 75 percent by weight of component (a), based upon the total weight of components (a) and (b), and approximately 25 to approximately 75 percent by weight of component (b), based upon the total weight of components (a) and (b).
32. A polymer blend according to Claim 22 which comprises approximately 30 percent by weight of component (a), based upon the total weight of components (a) and (b), and approximately 70 percent by weight of component (b), based upon the total weight of components (a) and (b).
33. A polymer blend according to Claim 22 wherein component (a) comprises approximately 15 to 35 mole percent of moiety I and approximately 65 to 85 mole percent of moiety II.
34. A polymer blend according to Claim 22 wherein component (b) comprises approximately 40 to 60 mole percent of moiety I, approximately, 20 to 30 mole percent of moiety II, approximately 5 to 30 mole percent of moiety III, and approximately 0 to 15 mole percent of moiety IV.
35. A polymer blend according to Claim 22 wherein the aromatic rings of the polymer components are substantially free of ring substitution.
36. A polymer blend according to Claim 22 which following injection-molding is capable of exhibiting a tensile strength of at least 35,000 psi.
37. A polymer blend according to Claim 22 which following injection-molding is capable of exhibiting a tensile strength of at least 40,000 psi.
38. A polymer blend according to Claim 22 which following injection-molding is capable of exhibiting a tensile strength of at least 45,000 psi.
39. A molding compound comprising the polymer blend of Claim 22 which incorporates approximately 1 to approximately 60 percent by weight, based upon the total weight of the molding compound, of a solid filler and/or reinforcing agent.
40. A molded article comprising the polymer blend of Claim 22.
41. A melt extruded three-dimensional article comprising the polymer blend of Claim 22.
42. A shaped article comprising the polymer blend of Claim 22 which has been subjected to heat treatment in a non-oxidizing atmosphere at approximately 10°C. to 30°C. below the melting temperature of the polymer blend.
43. A polymer blend which is capable of being melt-processed at a temperature in the range of approximately 280°C.
to 330°C. formed by melt-mixing which when molten is capable of exhibiting an anisotropic melt phase and which following injection-molding is capable of exhibiting at least one property selected from the group consisting of tensile strength, tensile modulus, flexural strength, and flexural modulus which exceeds that of each of the polymeric components of the blend when separately injection-molded comprising:
(a) approximately 25 to approximately 75 percent by weight, based upon the total weight of components (a) and (b), of a melt-processable wholly aromatic polyester which is capable of forming an anisotropic melt phase and which is substantially free of amide linkages and which consists essentially of approximately 27 mole percent of recurring 6-oxy-2-naphthoyl moieties and approximately 73 mole percent of recurring 4-oxybenzoyl moieties; and (b) approximately 25 to approximately 75 percent by weight, based upon the total weight of components (a) and (b), of a melt-processable poly(ester-amide) which is capable of forming an anisotropic melt phase and which consists essentially of approximately 60 mole percent of recurring 6-oxy-2-naphthoyl moieties, approximately 20 mole percent of recurring terephthaloyl moieties, and approximately 20 mole percent of recurring 4-oxyaminophenylene moieties.
to 330°C. formed by melt-mixing which when molten is capable of exhibiting an anisotropic melt phase and which following injection-molding is capable of exhibiting at least one property selected from the group consisting of tensile strength, tensile modulus, flexural strength, and flexural modulus which exceeds that of each of the polymeric components of the blend when separately injection-molded comprising:
(a) approximately 25 to approximately 75 percent by weight, based upon the total weight of components (a) and (b), of a melt-processable wholly aromatic polyester which is capable of forming an anisotropic melt phase and which is substantially free of amide linkages and which consists essentially of approximately 27 mole percent of recurring 6-oxy-2-naphthoyl moieties and approximately 73 mole percent of recurring 4-oxybenzoyl moieties; and (b) approximately 25 to approximately 75 percent by weight, based upon the total weight of components (a) and (b), of a melt-processable poly(ester-amide) which is capable of forming an anisotropic melt phase and which consists essentially of approximately 60 mole percent of recurring 6-oxy-2-naphthoyl moieties, approximately 20 mole percent of recurring terephthaloyl moieties, and approximately 20 mole percent of recurring 4-oxyaminophenylene moieties.
44. A polymer blend according to Claim 43 which following injection-molding is capable of exhibiting at least two properties selected from the group consisting of tensile strength, tensile modulus, flexural strength, and flexural modulus which exceed those of each of the polymeric components of the blend when separately injection-molded.
45. A polymer blend according to Claim 43 which following injection-molding is capable of exhibiting at least three properties selected from the group consisting of tensile strength, tensile modulus, flexural strength, and flexural modulus which exceed those of each of the polymeric components of the blend when separately injection-molded.
46. A polymer blend according to Claim 43 which following injection-molding is capable of exhibiting a tensile strength, tensile modulus, flexural strength, and flexural modulus which exceed those of each of the polymeric components of the blend when separately injection-molded.
47. A polymer blend according to Claim 43 wherein polymer components (a) and (b) each exhibit an inherent viscosity in the range of approximately 2.0 to 12.0 dl./g. when dissolved in a concentration of 0.1 percent by weight in pentafluorophenol at 60°C.
48. A polymer blend according to Claim 43 which comprises approximately 30 percent by weight of component (a), based upon the total weight of components (a) and (b), and approximately 70 percent by weight of component (b), based upon the total weight of components (a) and (b).
49. A polymer blend according to Claim 43 which following injection-molding is capable of exhibiting a tensile strength of at least 35,000 psi.
50. A polymer blend according to Claim 41 which following injection-molding is capable of exhibiting a tensile strength of at least 44,000 psi.
51. A polymer blend according to Claim 43 which following injection-molding is capable of exhibiting a tensile strength of at least 45,000 psi.
52. A molding compound comprising the polymer blend of Claim 43 which incorporates approximately 1 to approximately 60 percent by weight, based upon the total weight of the molding compound, of a solid filler and/or reinforcing agent.
53. A molded article comprising the polymer blend of Claim 43.
54. A melt-extruded three-dimensional article comprising the polymer blend of Claim 43.
55. A shaped article comprising the polymer blend of Claim 43 which has been subjected to heat treatment in a non-oxidizing atmosphere at approximately 10°C. to 30°C. below the melting temperature of the polymer blend.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US06/670,184 US4567227A (en) | 1984-11-13 | 1984-11-13 | Blend of wholly aromatic polyester and poly(ester-amide) capable of exhibiting an anisotropic melt phase |
| US670,184 | 1984-11-13 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1261515A true CA1261515A (en) | 1989-09-26 |
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ID=24689343
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000495114A Expired CA1261515A (en) | 1984-11-13 | 1985-11-12 | Blend of wholly aromatic polyester and poly (ester-amide) capable of exhibiting an anisotropic melt phase |
Country Status (5)
| Country | Link |
|---|---|
| US (1) | US4567227A (en) |
| EP (1) | EP0183433B1 (en) |
| JP (1) | JPH0655878B2 (en) |
| CA (1) | CA1261515A (en) |
| DE (1) | DE3571143D1 (en) |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2505411B2 (en) * | 1986-03-24 | 1996-06-12 | ポリプラスチックス 株式会社 | Resin composition exhibiting anisotropy when melted |
| US4871817A (en) * | 1986-12-31 | 1989-10-03 | General Electric Company | Polyetherimide-liquid crystal polymer blends |
| US4835047A (en) * | 1987-05-14 | 1989-05-30 | Avraam Isayev | Wholly aromatic polyester fiber-reinforced polyetherimide composite and process for preparing same |
| JPH0698701B2 (en) * | 1987-05-22 | 1994-12-07 | ポリプラスチックス株式会社 | Method for modifying liquid crystalline polyester resin moldings |
| SE8702840D0 (en) * | 1987-07-10 | 1987-07-10 | Plm Ab | BARRIERFORSTERKNING |
| DE3734645C1 (en) * | 1987-10-13 | 1988-12-15 | Inventa Ag | Molded body |
| ES2010297A6 (en) * | 1988-07-27 | 1989-11-01 | Cables Comunicaciones | A process for the preparation of aromatic thermotropic copolyesteramides,and copolyesteramides corresponding thereto. |
| US5147967A (en) * | 1988-10-11 | 1992-09-15 | Amoco Corporation | High strength polymer of hydroquinone poly(iso-terephthalate) containing residues of p-hydroxybenzoic acid |
| NL8803181A (en) * | 1988-12-28 | 1990-07-16 | Stamicarbon | POLYMER COMPOSITION BASED ON POLYMER AND A POLYESTERAMIDE. |
| DE3900708A1 (en) * | 1989-01-12 | 1990-07-19 | Basf Ag | IMPLANT MATERIALS |
| US5098940A (en) * | 1989-04-27 | 1992-03-24 | Amoco Corporation | Crystalline polyphthalamide composition having improved properties |
| US5393848A (en) * | 1990-01-16 | 1995-02-28 | Hoechst Celanese Corp. | Process for forming improved liquid crystalline polymer blends |
| US5364905A (en) * | 1991-04-26 | 1994-11-15 | The Goodyear Tire & Rubber Company | Process for the in-situ formation of reinforcing members in an elastomer and elastomer made thereby |
| WO1993004127A1 (en) * | 1991-08-14 | 1993-03-04 | Hoechst Celanese Corporation | Process for forming improved liquid crystalline polymer blends |
| US5262473A (en) * | 1991-11-29 | 1993-11-16 | Enichem America Inc. | Polymer molding compositions containing polycarbonates and polyesters and liquid crystalline polymers |
| US5981007A (en) * | 1992-03-31 | 1999-11-09 | Foster-Miller, Inc. | Extruded thermoplastic, liquid crystalline polymers and blends thereof having a planar morphology |
| CA2112781A1 (en) * | 1993-01-13 | 1994-07-14 | Paul C. Yung | Blends of liquid crystalline polymers and poly(arylene sulfide)s having reduced viscosities |
| JP4221522B2 (en) * | 1996-02-29 | 2009-02-12 | スリーエム カンパニー | Optical thin film with a co-continuous phase |
| US20020037377A1 (en) | 1998-02-03 | 2002-03-28 | Schmidt Steven L. | Enhanced oxygen-scavenging polymers, and packaging made therefrom |
| WO1999038914A2 (en) * | 1998-02-03 | 1999-08-05 | Continental Pet Technologies, Inc. | Enhanced oxygen-scavenging polymers, and packaging made therefrom |
| JP2001261946A (en) * | 2000-03-14 | 2001-09-26 | Polyplastics Co | Liquid crystal polymer composition and molding method |
| US6660182B2 (en) | 2000-09-01 | 2003-12-09 | Ticona Llc | Blends of stretchable liquid crystal polymers with thermoplastics |
| JP5110787B2 (en) * | 2005-10-28 | 2012-12-26 | 上野製薬株式会社 | Liquid crystal polymer blend and composition comprising the same |
Family Cites Families (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5465747A (en) * | 1977-11-04 | 1979-05-26 | Motoo Takayanagi | High molecular composite body |
| EP0030417B2 (en) * | 1979-11-30 | 1994-03-30 | Imperial Chemical Industries Plc | Compositions of melt-processable polymers having improved processibility, and method of processing |
| US4489190A (en) * | 1980-06-11 | 1984-12-18 | Celanese Corporation | Blend of polyalkylene terephthalate and wholly aromatic polyester |
| US4267289A (en) * | 1980-07-03 | 1981-05-12 | Celanese Corporation | Blend of wholly aromatic polyesters |
| US4460736A (en) * | 1980-07-03 | 1984-07-17 | Celanese Corporation | Blend of sulfone polymer and wholly aromatic polyester |
| US4460735A (en) * | 1980-07-03 | 1984-07-17 | Celanese Corporation | Blend of polycarbonate and wholly aromatic polyester |
| US4276397A (en) * | 1980-07-07 | 1981-06-30 | Celanese Corporation | Blend of polyarylene sulfide and wholly aromatic polyester |
| US4439578A (en) * | 1981-11-09 | 1984-03-27 | Celanese Corporation | Use of liquid crystal polymer particulates having a high aspect ratio in polymeric molding resins to suppress melt dripping |
| US4632798A (en) * | 1983-07-27 | 1986-12-30 | Celanese Corporation | Encapsulation of electronic components with anisotropic thermoplastic polymers |
| US4547547A (en) * | 1983-12-01 | 1985-10-15 | The Dow Chemical Company | Polymer blends |
-
1984
- 1984-11-13 US US06/670,184 patent/US4567227A/en not_active Expired - Lifetime
-
1985
- 1985-11-11 JP JP60252595A patent/JPH0655878B2/en not_active Expired - Fee Related
- 1985-11-12 CA CA000495114A patent/CA1261515A/en not_active Expired
- 1985-11-13 DE DE8585308255T patent/DE3571143D1/en not_active Expired
- 1985-11-13 EP EP85308255A patent/EP0183433B1/en not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| EP0183433A1 (en) | 1986-06-04 |
| JPH0655878B2 (en) | 1994-07-27 |
| JPS61120851A (en) | 1986-06-07 |
| US4567227A (en) | 1986-01-28 |
| DE3571143D1 (en) | 1989-07-27 |
| EP0183433B1 (en) | 1989-06-21 |
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